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PowerMax™ Composite Idler Pulleys and Sprockets  Lightweight, Quiet, Durable


Fenner Drives is the industry leader in composite products for industrial power transmission and material handling applications. PowerMax Idler Pulleys and Sprockets offer superior composite design for years of successful service, even in the harshest surroundings. The use of high strength glass-reinforced nylon makes our pulleys and sprockets ideal for washdown applications and corrosive environments (optional stainless steel bearings essential for full resistance).

PowerMax Idler Pulleys and Sprockets are perfect for use as high speed idlers on conveyors, packaging equipment, lawn and garden equipment, floor cleaning machines and in many other power transmission applications.

Our extensive selection of stock sizes provides for immediate product availability. Should your application require something special, Fenner Drives in-house engineering can help you design a custom idler pulley or sprocket that fits both your budget and your production lead time requirements.

Combine PowerMax Composite Idlers and Sprockets with our T-Max Automatic Linear and Rotary Tensioners for a simple "off the shelf" tensioning solution.

The PowerMax Technology Advantage

  • Molded of premium quality, high-strength, glass-reinforced nylon composite
  • Insertion molded ABEC 1 high-precision bearings
  • Precision sealed bearings are greased for life — never need relubrication
  • State-of-the-art precision molding assures consistent quality parts
  • Finite Element Stress Analysis (FEA) assures superior product performance
  • Stringent product testing and quality checks ensure that you only get the best products for years of dependable service
Benefits of PowerMax Idler Pulleys and Sprockets
  • Light-weight
  • Corrosion resistant
  • Quiet
  • Reduced axial and radial runout
  • Excellent concentricity
  • Longer belt, cable and chain life
  • Pulleys ideal for use with flat, round, or V-section belts and cables
  • Sprockets available for #30 – #85 roller chain
Fenner Drives Mounting Adapters
  • For simplified mounting of PowerMax Idlers
  • Made from high quality sintered iron
  • Available as bore, clevis, and shoulder adapters
  • Easy press-fit installation
  • Factory installation available at no extra charge

PowerMax Idler Pulley & Sprocket Specials

If you don't see the pulley or sprocket you need among our standard offering, don't despair. There are a number of other options to consider. For instance, most PowerMax Pulleys can be supplied with a special 5/8" or 3/4" bore bearing if required. (Use of these special bore bearings does not allow the use of our standard mounting adapters.) Stainless-steel bearings (17mm bore) are also available for full resistance to corrosive environments or washdown applications. Also, for light drive applications, PowerMax Idler Pulleys can be supplied with sintered metal drive hubs. Bore sizes of 1/2", 5/8", 3/4" are available with standard keyways and setscrews. Consult factory for more information.

New pulleys are simple. Our Modular Mold System means less lead time, lower cost and competitive prices. Contact the factory with your special requirements.


Industry: Pumps

Application: Commercial Power Washer

Problem: Customer's application involves a vertical drive, i.e. the motor is piggy backed over the pump. Did not want to fabricate a motor base with jack screws to raise and lower motor.

Solution: Used a PowerMax Flat Idler Pulley fixed on the backside of the belt. Pump mounting is slotted for horizontal movement. When moving the pump to the left the idler position results in the belt being tensioned.


Industry: Material Handling

Application: Concrete Blocks Roller Conveyor

Problem: Original idler pulleys were fitted with small bearings that would freeze up from the contaminants in the environment. The small bearing also transmitted vibrations to the idler pulley which resulted in blemishes on the block.

Solution: 2.0" flat idler pulley from Fenner Drives. Idler has a much larger (diameter) bearing which will transmit less vibration to the pulley surface. Bearing conforms to ABEC-1 standards and utilizes two wiping seals to keep lubricant in and contaminants out. The larger bearing will be less susceptible to "freezing" and result in less blemishes, caused by vibration, to the blocks.


Industry: Material Handling

Application: Assembly Transport Line

This transport line consists of modular workstations which are joined together to create assembly cells. These stations have tracks upon which carts slide transporting the product through the build process. In some instances a means of driving the cart on a transport line may be required. For these requirements the customer has developed a modular belt drive system. Power from the belt is transferred to the cart via a striker bar assembly which is fastened to the underside of the cart's body.

Problem: Needed to reduce overall machine weight. Metallic v-pulleys added to overall weight.

Solution: All pulleys in the drive system, except the motor pulley, were changed to premium quality high strength glass-reinforced nylon. Pulleys are furnished with a precision sealed bearing that is greased for life. Molded belt surface means smooth and quiet operation. Lighter weight means less energy used at start-up and during the work cycle. The photos below show the head and tail section only of the conveyor.

Reasons for using Composite Idler Pulleys:

  • Precision sealed bearings are greased for life - never need relubrication
  • Lightweight
  • Quiet operation
  • Longer belt life
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